Recommended Practice on Remotely Operated Tool (ROT) Intervention Systems ANSI/API RECOMMENDED PRACTICE 17M FIRST EDITION, APRIL 2004 REAFFIRMED: JANUARY 2009 ISO 13628-9:2000 (Identical), Petroleum and natural gas industries—Design and operation of subsea production systems—Part 9: Remotely Operated Tool (ROT) intervention systems Special Notes API publications necessarily address problems of a general nature With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that 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formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard API does not represent, warrant, or guarantee that such products in fact conform to the applicable API standard These materials are subject to copyright claims of ISO, ANSI and API All rights reserved No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C 20005 Copyright © 2004 American Petroleum Institute API Recommended Practice 17M / ISO 13628-9 API Foreword This standard shall become effective on the date printed on the cover but may be used voluntarily from the date of distribution Standards referenced herein may be replaced by other international or national standards that can be shown to meet or exceed the requirements of the referenced standard This American National Standard is under the jurisdiction of the API Subcommittee on Subsea Production systems This standard is considered identical to the English version of ISO 13628-9:2000 ISO 136289:2000 was prepared by Technical Committee ISO/TC 67 Materials, equipment and offshore structures for the petroleum and natural gas industries, SC Drilling and production equipment API publications may be used by anyone desiring to so Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict Suggested revisions are invited and should be submitted to API, Standards department, 1220 L Street, NW, Washington, DC 20005, standards@api.org ii Contents Page API Foreword ii Foreword iv Introduction .v Scope .1 2.1 2.2 Terms, definitions and abbreviated terms Terms and definitions Abbreviated terms 3.1 3.2 3.3 3.4 3.5 System selection General Deck handling equipment Intervention control system (ICS) Deployment/landing equipment Tools for primary intervention tasks 4.1 4.2 4.3 4.4 4.5 4.6 Functional requirements and recommendations General Deployment and landing requirements and recommendations Surface equipment 10 Control system requirements and recommendations 12 Tie-in operations 15 Module replacement .18 Test requirements and recommendations 19 Interfaces .19 Bibliography 24 ISO 13628-9:2000(E) API Recommended Practice 17M / ISO 13628-9 Foreword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies) The work of preparing International Standards is normally carried out through ISO technical committees Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part Draft International Standards adopted by the technical committees are circulated to the member bodies for voting Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote Attention is drawn to the possibility that some of the elements of this part of ISO 13628 may be the subject of patent rights ISO shall not be held responsible for identifying any or all such patent rights International Standard ISO 13628-9 was prepared by Technical Committee ISO/TC 67, Materials, equipment and offshore structures for petroleum and natural gas industries, Subcommittee SC 4, Drilling and production equipment ISO 13628 consists of the following parts, under the general title Petroleum and natural gas industries — Design and operation of subsea production systems: ¾ Part 1: General requirements and recommendations ¾ Part 2: Flexible pipe systems for subsea and marine applications ¾ Part 3: Through flowline (TFL) systems ¾ Part 4: Subsea wellhead and tree equipment ¾ Part 5: Subsea control umbilicals ¾ Part 6: Subsea production control systems ¾ Part 7: Workover/completion riser systems ¾ Part 8: Remotely Operated Vehicle (ROV) interfaces on subsea production systems ¾ Part 9: Remotely Operated Tool (ROT) intervention systems iv iv © ISO 2000 – All rights reserved API Recommended Practice 17M / ISO 13628-9 ISO 13628-9:2000(E) Introduction This part of ISO 13628 is considered to be closely related to ISO 13628-1 and ISO 13628-8 ISO 13628-1 provides general requirements and overall recommendations for development of complete subsea production systems for the petroleum and natural gas industries, from design to decommissioning, and gives a description of how the ROT intervention systems relate to the total subsea production system The objective of subsea intervention systems, including vessel and deck handling equipment, is to facilitate safe and efficient intervention on subsea installations v © ISO 2000 – All rights reserved v API Recommended Practice 17M / ISO 13628-9 INTERNATIONAL STANDARD ISO 13628-9:2000(E) Petroleum and natural gas industries — Design and operation of subsea production systems — Part 9: Remotely Operated Tool (ROT) intervention systems Scope This part of ISO 13628 provides functional requirements and recommendations for ROT intervention systems and interfacing equipment on subsea production systems for the petroleum and natural gas industries This part of ISO 13628 does not cover manned intervention and ROV-based intervention systems (e.g for tie-in of sealines and module replacement) Vertical wellbore intervention, internal flowline inspection, tree running and tree running equipment are also excluded from this part of ISO 13628 Terms, definitions and abbreviated terms For the purposes of this part of ISO 13628, the following terms, definitions and abbreviated terms apply 2.1 Terms and definitions 2.1.1 subsea intervention all work carried out subsea 2.1.2 primary intervention all work carried out during the scheduled intervention task 2.1.3 ROT system dedicated, unmanned, subsea tools used for remote installation or module replacement tasks that require lift capacity beyond that of free-swimming ROV systems NOTE The ROT system comprises wire-suspended tools with control system and support-handling system for performing dedicated subsea intervention tasks They are usually deployed on liftwires or a combined liftwire/umbilical Lateral guidance may be via guidewires, dedicated thrusters or ROV assistance 2.1.4 deployment system all equipment involved in the launch and recovery of the ROT system 2.1.5 heave-compensated system system that limits the effect of vertical vessel motion on the deployed ROT system © ISO 2000 – All rights reserved ISO 13628-9:2000(E) API Recommended Practice 17M / ISO 13628-9 2.1.6 skid system storage, transportation, lifting and testing frames to facilitate movement of the ROT systems and the modules and components to be replaced or installed NOTE Skids are used in combination with a skidding system 2.1.7 sealines all pipelines, flowlines, umbilicals and cables installed on the seabed 2.1.8 termination head part of the PICS interfacing with the end of the sealine 2.1.9 pull-in head part of the pull-in system acting as attachment point for the end of the pull-in wire 2.2 Abbreviated terms CB centre of buoyancy CF connection function CG centre of gravity CT connection tool FAT factory acceptance test HPU hydraulic power unit ICS intervention control system ID internal diameter IP ingress protection LCC life cycle cost MQC multi quick connector NAS National Aerospace Standard Institute PGB permanent guide base PICS pull-in and connection system PIF pull-in function PIT pull-in tool ROT remotely operated tool ROV remotely operated vehicle SPS subsea production system 2 © ISO 2000 – All rights reserved ISO 13628-9:2000(E) API Recommended Practice 17M / ISO 13628-9 b) The umbilical design shall be suitable for the application required, particularly in respect to torque balance, tensile strength, elongation, fatigue bending and rough handling, all in combination with good flexibility and low mass to ensure ease of handling and operation c) A combined umbilical/lifting wire should be considered Breaking strength and fatigue resistance shall be documented d) The umbilical shall be designed able to operate under full load with all the umbilical on the winch drum, accounting for heat production in the umbilical e) In umbilicals containing hydraulic lines, the hydraulic return line should always have a pressure higher than ambient in order to prevent seawater ingress Alternatively, other suitable seawater ingress-prevention facilities may be considered f) The umbilical terminations should be of lightweight design to enable handling and connection/disconnection by a maximum of two operators g) The umbilical shall be fitted with a ground wire of necessary size to prevent electrical potential differences between the ROT system and the surface equipment To prevent black-out, sufficient high voltage isolation between the ROT system and the vessel's electrical system shall be provided h) The umbilical subsea termination shall include an umbilical bend restrictor i) The umbilical MQC plates shall be easy to operate Guidance, alignment and orientation features shall be provided to ensure correct coupler alignment and prevent coupler damage during connection and disconnection j) The MQC plate should be the weak link for the umbilical k) The umbilical and liftwire attachments shall include a feature for safe disconnection of the umbilical and the liftwire from the ROT in case of vessel drift-off 4.4.4 Subsea control system The following requirements and recommendations apply a) The ROT system may be operated by use of a subsea HPU, either ROT-mounted or via an ROV b) The HPU installed should be mounted on a subframe isolated from the lifting frame by shock-absorbing elements (e.g elastomer mounts) c) All hydraulic components in the ROT system should be compatible with the hydraulic fluid used in the surface control system d) The ROT system shall have provision for flushing of the hydraulic system e) All hydraulic lines and components shall be sufficiently protected from overpressure, e.g by adequate use of pressure-reducing or -relief valves f) Subsea electrical and electronic units shall be properly protected Atmospheric containers and/or oilfilled pressure-compensated compartments should be used where applicable g) Alarm shall be provided upon critical low pressure and reservoir levels in the hydraulic system When an ROV is used in an override or contingency function transfer, e.g power and/or control through a hot-stab connection, the following requirements and recommendations apply Reference may also be made to recognized industry standards 14 14 © ISO 2000 – All rights reserved API Recommended Practice 17M / ISO 13628-9 ISO 13628-9:2000(E) ¾ The transfer of fluid between the two systems shall be based on fluid compatibility Alternatively, a hydraulic motor/pump unit placed in the ROV skid should be considered to avoid interference of hydraulic fluid between the ROV system and the ROT system ¾ When an ROV is docked on the ROT, the ROV should still be able to perform complementary work and monitoring tasks on accessible and viewable areas 4.5 Tie-in operations 4.5.1 General This subclause states functional requirements and recommendations to the PIF and the CF The PICS includes in general the following main equipment: a) tools for pull-in and connection, either as separate tools or a combined tool; b) connectors and seal assemblies; c) hubs, caps and terminations; d) pull-in porches/alignment structures The subsea electrical connection system shall be covered by a recognized industry standard 4.5.2 Pull-in tool (PIT) The following requirements and recommendations apply a) The PIT shall perform the complete pull-in operation in a single run and secure the sealine in a safe and defined position b) The PIT shall be mechanically locked to the subsea structure or the inboard hub during pull-in operations c) A subsea winch should be used for final pull-in sequence Alternatively, a surface pull-in winch/take-up reel may be used d) All PIT elements shall be designed for the maximum sealine pull-in force e) The PIT should be capable of performing pull-in without back-tension in the sealine f) Skew load on the PIT shall be included based on the maximum entry angle of the wire g) If direct ROV pick-up of the pull-in wire is not possible, a wire delivery mechanism shall be included h) The ROV shall establish the connection between the pull-in wire and the termination head/pull-in head i) The PIT or the ROV shall be able to release the pull-in wire j) If a pull-in head is mounted on the outboard hub, this shall be removed either by the PIT at completion of pullin, by ROV, or by the CT prior to commencement of hub stroke-in 4.5.3 Connection function The following requirements and recommendations apply a) The CT should be able to perform the complete connection or disconnection operation in a single run 15 © ISO 2000 – All rights reserved 15 ISO 13628-9:2000(E) API Recommended Practice 17M / ISO 13628-9 b) Safe storage positions for the outboard hub should be available both before a connection and after a disconnection c) The CT shall be designed to meet the maximum connection force required for mating or demating of the fixed and the stroking hub d) The CT shall be mechanically locked to subsea structure or the fixed hub during connection operations e) Loads from the sealine shall not cause any leakage in the connection f) The stroking force generated by the CT shall take into account all forces transmitted to the connection system g) The CT shall have the capability to enter, catch and align the hubs at a defined worst-misalignment condition h) It shall be possible to replace the seal assembly either by the CT or by an ROV If a spool-piece connector is used, the seals shall be a part of the connector assembly (rather than the hubs), in which case it shall be possible to retrieve the complete connector, in order to replace the seals at the surface i) If clamp connectors are used, the CT, or where applicable an ROV, shall incorporate facilities to ensure that the make-up and break-out torque applied is kept within the specified torque range In addition, turn-counting of jack-screw revolutions should be considered for enhanced operation feedback and operator information j) The CT should include means of testing the seal integrity after a connection is made up k) The CT should be capable of connecting a single subsea pig-launcher to the inboard hub of a single-bore sealine 4.5.4 Connector and seal assembly The following requirements and recommendations apply a) Any preload shall be maintained mechanically without use of hydraulic pressure b) The connection shall withstand cyclic loads caused by pressure, temperature and external loads c) For secondary seals and back-up seals, elastomer materials with verified service performance may be used d) The connectors for the sealines shall permit repeatable connections and disconnection, preferably without the need for replacement of the seals e) Connectors should be of a standard size/rating to facilitate beneficial interfacing with the CT design Emphasis should also be put on standardizing the interface between the connector and the CT f) The clamp connector should be replaceable remotely without retrieval of either hub to surface g) Pigging requirements shall be taken into consideration when selecting seal ID h) The connector should allow for external pressure testing of the connection If so, the annular area between the primary metal seal and the environmental seal shall be vented to avoid pressure build-up in case a leak develops in the metal-to-metal seal i) Multibore connections shall have a system for orienting the seal assembly relative to the hubs j) Connectors shall be designed for uniform force distribution around the hub circumference k) Connectors shall incorporate features that prevent unintentional release due to impact from tools, ROV, falling objects, tool failures or due to any other operational loads l) The load capacity of the connections shall ensure seal integrity for all operational loads 16 16 © ISO 2000 – All rights reserved API Recommended Practice 17M / ISO 13628-9 ISO 13628-9:2000(E) m) Both sealine and header shall have sufficient load capacity to withstand pull-in, stroke-in and alignment loads In addition, residual preload for final alignment of the hubs shall be taken into consideration Adequate assisting marine operations to protect sealine from overstressing should be considered n) The distance between fixed and stroking hubs shall enable installation/retrieval of applicable equipment, such as pull-in head, caps, seals and connectors Required back-stroke shall consider interfacing equipment o) It shall be possible to perform seal-seat inspection and cleaning prior to final connection p) The resulting face-to-face angular gap after engaging the hubs shall allow the clamp to enter the hubs with proper margin and provide final alignment and make-up of the connection 4.5.5 Hubs, caps and termination heads The following requirements and recommendations apply a) The fixed hub shall meet the PICS flexibility (stroke and alignment) requirements b) Hydraulic lines should include check valves to prevent loss of hydraulic fluid or ingress of water and dirt when disconnected In case of risk for clogging of check valves, the hydraulic lines should be fitted with protection caps when disconnected c) All surplus bores in standard multibore hubs shall be permanently plugged d) In case of defect lines in the umbilical, it shall be possible for multibore seal plates to utilize the spare lines in the umbilical by means of by-pass solutions e) Hubs should not represent a flow restriction f) Hubs in piggable lines should have inside diameters flush with the line g) The hub seal preparations shall, in case of damage, accommodate a contingency seal surface by installation of modified seal rings h) Required pressure caps/blind hubs should be installed/retrieved by use of the ROT Alternatively, the caps can be installed/retrieved by an ROV tool The pressure caps shall be connected by means of a connector and shall have the same rating as the hub/bores it blinds off i) The long-term protection cap shall include means of protecting the seal area The long-term protection cap shall be installed on surface and retrieved by the ROV or alternatively by the ROT j) The long-term protection caps shall prevent intrusion of salt water to the hub sealing areas and should not be pressure-containing If required, a pressure-equalization device should be included k) The short-term protection cap shall protect against dirt and seawater circulation and be installed/retrieved by ROV l) The inboard protection and pressure caps shall include means of venting the manifold piping m) The inboard protection and pressure caps should include means of filling of manifold preservation fluid, to facilitate a complete filling of the manifold piping n) There shall be provision for installation of dirt protection plugs on any vital part o) The termination head shall be optimized with regards to mass, dimensions and interface with the sealine p) The termination head shall withstand all loads from the sealines and transmit them into the subsea structure 17 © ISO 2000 – All rights reserved 17 ISO 13628-9:2000(E) API Recommended Practice 17M / ISO 13628-9 q) The termination head shall have wire-attachment points for laydown purposes or in case a pull-out of the sealine is required r) The termination head/pull-in head and corresponding clamp shall prevent accidental release during all phases of the installation and pull-in operations s) The pull-in head shall enable connection of an ROV-installed hotstab for flushing and pressure-testing purposes The possibility of using the hotstab for pigging purposes shall be evaluated t) The termination head/pull-in head shall enable bleed-off of internal pressure u) The pull-in head should be retrievable to surface v) The umbilical termination head shall have a marking system for rotation identification w) The umbilical termination head may have provision for installation of electrical coupler receptacles x) The umbilical termination head should have provisions for installation of removable plugs and covers, protecting the electrical coupler receptacles 4.5.6 Pull-in porches/alignment structures The following requirements apply a) The pull-in porches shall be designed to withstand or to be protected from snag loads, e.g from lift wires and guidewires b) Maximum entry angles of the termination head shall be defined as it enters the alignment funnel 4.6 Module replacement This subclause contains functional requirements and recommendations for the installation or replacement of modules The following general requirements and recommendations apply a) The ROT system shall provide a safe locking of the replaceable module during handling, deployment/retrieval and operation b) Replacement of modules should be based on vertical retrieval and re-entry to the landing receptacle c) If power failure occurs or is switched off during running, the replaceable module shall remain locked to the ROT d) The module to be installed should be landed in a two-step sequence: 1) landing the dedicated ROT system on the subsea landing structure; 2) final landing and alignment of the module onto the subsea interface; e) When a module is to be retrieved, the ROT system shall be designed with sufficient flexibility to self-align and freely enter the module mating point f) Modules interfacing pressurized equipment (e.g valve insert, clamp connection) shall have provisions for verifying that internal pressure is bled off It should also be possible to verify the seal integrity on connection points 18 18 © ISO 2000 – All rights reserved API Recommended Practice 17M / ISO 13628-9 ISO 13628-9:2000(E) Test requirements and recommendations The following requirements and recommendations apply a) If the ROT system design undergoes any changes in fit, form, function or material, the manufacturer shall document the impact of such changes on the performance of the system A system design that undergoes a substantial change becomes a new design, requiring requalification b) New designs shall be evaluated with respect to requirement for qualification and wet testing c) The ROT system shall undergo a FAT prior to delivery of the system d) All functions in the ROT system, including contingency functions, shall be verified e) The ROT system shall have provisions for surface testing prior to deployment f) The ROT system should have its interfaces tested and verified on all working location(s) on the SPS g) ROT systems and modules should be drop-tested to demonstrate the system's ability to withstand dynamic shocks as specified All functions shall be tested and verified before and after the drop test h) All structural, mechanical and control (electrical and hydraulic) internal interfaces within the ROT system shall be verified i) All structural, mechanical and control (electrical and hydraulic) external interfaces between the ROT system and interfacing systems and components shall be verified j) All dimensions and masses for the ROT system shall be verified k) The ROT system stability (CG/CB in air and water) shall be verified Regarding ROTs for module replacement, the stability shall be verified with and without the replaceable module l) Entry and landing of the ROT system at maximum entry angle shall be verified m) All capacities such as torque output, stroking forces, override forces/torques shall be verified n) Proper calibration of all relevant equipment such as sensors, switches, gauges, etc shall be verified o) ROV access for monitoring, inspection and operation of relevant ROT functions (including back-up) shall be verified Interfaces The various detailed internal and external interfaces shall be identified and sorted out on a project to project basis The interfaces identified below are included as a guideline for establishing an interface register a) Vessels and rigs Consider features such as: 1) handling, skidding and deployment/cursor system; 2) electric and electromagnetic compatibility; 3) provision of pneumatic and hydraulic power; 19 © ISO 2000 – All rights reserved 19 ISO 13628-9:2000(E) b) API Recommended Practice 17M / ISO 13628-9 4) deck facilities and interferences, such as moonpool size; 5) effect on vessel fire-fighting and life safety; 6) dimensions and mass limitations of ROT and modules; 7) control container/room facility, including communication and monitoring system; 8) vessel stationkeeping; 9) motion characteristics and scheduling of simultaneous operations Subsea structures (templates, manifolds and riser bases) Consider features such as: c) 1) layout and dimensions of landing area; 2) guideposts; 3) locking mechanisms and the pull-in funnel/alignment structure; 4) process piping /manifold system; 5) sealine snag loads; 6) others Subsea tree systems (including WOCS) Consider features such as: d) 1) layout and dimensions of PGB landing area; 2) guideposts, locking mechanisms and the pull-in funnel/alignment structure; 3) process piping, wellhead load capacities, tolerances, sealines snag loads; 4) others Production control systems Consider features such as: e) 1) number of lines; 2) sizes; 3) pressures; 4) fluids; 5) electrical connections; 6) others Flowlines Consider features such as: 20 20 © ISO 2000 – All rights reserved API Recommended Practice 17M / ISO 13628-9 1) size; 2) rating; 3) stiffness; 4) termination; 5) material; 6) expansion forces; 7) pull-in forces; 8) rotational forces; 9) snagloads; ISO 13628-9:2000(E) 10) backstroke limitations; 11) others f) Umbilicals Consider features such as: 1) size; 2) rating; 3) stiffness; 4) umbilical termination; 5) material; 6) expansion forces; 7) pull-in forces; 8) rotational forces; 9) snagloads; 10) backstroke limitations; 11) electrical connections; 12) others g) Risers Consider features such as: 1) size; 2) rating; 3) stiffness; 21 © ISO 2000 – All rights reserved 21 ISO 13628-9:2000(E) h) 4) termination; 5) material; 6) forces; 7) others API Recommended Practice 17M / ISO 13628-9 Testing Consider features such as: i) 1) test facility location; 2) test equipment; 3) others Transportation Consider features such as: j) 1) site location; 2) method of transport; 3) mass and size limitations; 4) sea-fastening; 5) others Installation of structures Consider features such as: k) 1) levelling requirements; 2) positioning tolerances; 3) installations; 4) mass limitations; 5) others Installation of sealines Consider features such as: 1) survey; 2) pipelaying and umbilical installation; 3) sequences; 22 22 © ISO 2000 – All rights reserved API Recommended Practice 17M / ISO 13628-9 l) 4) trenching; 5) mattresses and rockdumping; 6) others ISO 13628-9:2000(E) ROV systems Consider features such as: 1) access for observation and inspection; 2) operation of ROV tools; 3) handling of pull-in wire; 4) operation of lockdown mechanisms and mechanical overrides; 5) cleaning of hubs; 6) others 23 © ISO 2000 – All rights reserved 23 ISO 13628-9:2000(E) API Recommended Practice 17M / ISO 13628-9 Bibliography [1] ISO 4406, Hydraulic fluid power — Fluids — Method for coding the level of contamination by solid particles [2] NAS 1638, National Aerospace Standard — Cleanliness requirements of parts used in hydraulic systems 24 24 © ISO 2000 – All rights reserved 2009 Publications Effective January 1, 2009 API Members receive a 30% discount where applicable Order Form Available through IHS: Phone Orders: 1-800-854-7179 The member discount does not apply to purchases made for the purpose of resale or for incorporation into commercial products, training courses, workshops, or other commercial enterprises 303-397-7956 303-397-2740 global.ihs.com Fax Orders: Online Orders: (Toll-free in the U.S and Canada) (Local and International) Date: ❏ API Member (Check if 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